Process for the production of chlorinated and fluorinated alkanes and alkenes in the presence of a catalyst

ABSTRACT

The invention provides a process for preparing 1,1,1-trifluoro-2,3-dichloropropane (243db), which process comprises contacting 3,3,3-trifluoropropene (1243zf) with chlorine in the presence of a catalyst, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal.

The invention relates to a process for preparing 1,1,1-trifluoro-2,3-dichloropropane. In particular, the invention relates to a process for preparing 1,1,1-trifluoro-2,3-dichloropropane from carbon tetrachloride and ethylene including the step of chlorinating 3,3,3-trifluoropropene.

The invention provides a process for preparing 1,1,1-trifluoro-2,3-dichloropropane, which process comprises contacting 3,3,3-trifluoropropene with chlorine (Cl₂) in the presence of a catalyst to produce 1,1,1-trifluoro-2,3-dichloropropane, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal.

The process of the invention provides a surprisingly clean and efficient means for preparing 1,1,1-trifluoro-2,3-dichloropropane from 3,3,3-trifluoropropene. For example, by using a catalyst comprising activated carbon, alumina and/or an oxide of a transition metal, lower temperatures can be used compared to without the use of such a catalyst. This is believed to result in less by-products and increase yield of 1,1,1-trifluoro-2,3-dichloropropane.

1,1,1-trifluoro-2,3-dichloropropane is also known as HFC-243db or just 243db. Unless otherwise stated, 1,1,1-trifluoro-2,3-dichloropropane will be referred to hereinafter as 243db. 3,3,3-trifluoropropene is also known as HFO-1243zf or just 1243zf. Unless otherwise stated, 3,3,3-trifluoropropene will be referred to hereinafter as 1243zf.

For the avoidance of doubt, by a catalyst which comprises activated carbon, alumina and/or an oxide of a transition metal, we include catalysts that are essentially only activated carbon, alumina and/or an oxide of a transition metal and catalysts that are activated carbon, alumina and/or an oxide of a transition metal modified, for example, by the addition of one or more metals (e.g. transition metals) and/or compounds thereof.

By “activated carbon”, we include any carbon with a relatively high surface area such as from about 50 to about 3000 m² or from about 100 to about 2000 m² (e.g. from about 200 to about 1500 m² or about 300 to about 1000 m²). The activated carbon may be derived from any carbonaceous material, such as coal (e.g. charcoal), nutshells (e.g. coconut) and wood. Any form of activated carbon may be used, such as powdered, granulated and pelleted activated carbon. Activated carbon which has been modified (e.g. impregnated) by the addition of Cr, Mn, Au, Fe, Sn, Ta, Ti, Sb, Al, Co, Ni, Mo, Ru, Rh, Pd and/or Pt and/or a compound (e.g. a halide) of one or more of these metals may be used.

Alumina which has been modified by the addition of Cr, Mn, Au, Fe, Sn, Ta, Ti, Sb, Al, Co, Ni, Mo, Ru, Rh, Pd and/or Pt and/or a compound (e.g. a halide) of one or more of these metals may be used.

An oxide of a transition metal that has been modified by the addition of Cr, Mn, Au, Fe, Sn, Ta, Ti, Sb, Al, Co, Ni, Mo, Ru, Rh, Pd and/or Pt and/or a compound (e.g. a halide) of one or more of these metals may be used.

A preferred oxide of a transition metal is an oxide of Cr, Ti, V, Zr, or Fe. For example, chromia (Cr₂O₃) alone or chromia that has been modified by the addition of Zn, Mn, Zr, Ni, Al and/or Mg and/or a compound of one or more of these metals may be used. Suitable chromia-based catalysts include those described in EP-A-0502605, EP-A-0773061, EP-A-957074, WO 98/10862 and WO 2006/106353. A preferred chromia-based catalyst is a zinc/chromia catalyst.

A preferred group of catalysts are catalysts which comprise activated carbon, alumina and/or chromia. Activated carbon is currently a preferred catalyst because it is cheap, readily available, effective and robust. Activated carbon is commercially available, e.g. from Sutcliffe-Speakman.

The process of the invention may be conducted in the vapour and/or liquid phase, preferably in the vapour phase. The process may be carried in the liquid phase using the 243db product as the solvent. The heat of reaction in such a process may be removed by boiling off the 243db product/solvent.

Typically, the process is conducted at a temperature of from about −100 to about 400° C., such as from about −80 to about 300° C. or −50 to about 250° C., e.g. from about 0 to about 200° C. or about 50 to about 150° C. The process may be conducted at a pressure of from about 0 to about 30 bara, such as from about 0.1 to about 20 bara or from about 0.5 to about 10 bara, e.g. from about 1 to about 5 bara.

The process of the invention can be carried out in any suitable apparatus, such as a static mixer, a tubular reactor, a stirred tank reactor or a stirred vapour-liquid disengagement vessel. Preferably, this or any other apparatus described herein is made from one or more materials that are resistant to corrosion, e.g. Hastelloy® or Inconel®. The process may be carried out batch-wise or continuously.

Typically, the molar ratio of 1243zf:chlorine in the chlorination process is from about 10:1 to about 1:5, such as from about 5:1 to about 1:2, for example from about 3:1 to about 1.5:1 (e.g. about 2.5:1 to about 1:1).

The chlorination process of the invention may be carried out photochemically, for example by exposing the reactants to UV radiation of a suitable wavelength, typically from about 190 to about 420 nm (such as monochromatic radiation, e.g. 254 nm). Any suitable catalyst of the invention selected from activated carbon, alumina and/or an oxide of a transition metal may be used in the photochemical process. Currently preferred catalysts include activated carbon and zinc oxide.

1243zf is commercially available (e.g. from Apollo Scientific Ltd, UK). Alternatively, 1243zf may also be prepared via a synthetic route starting from the cheap feedstocks carbon tetrachloride (CCl₄) and ethylene (see the reaction scheme is set out below). These two starting materials may be telomerised to produce 1,1,1,3-tetrachloropropane (see, for example, J. Am. Chem. Soc. Vol. 70, p 2529, 1948, which is incorporated herein by reference) (also known as HCC-250fb, or simply 250fb).

250fb may then be fluorinated to produce 1243zf and/or 1,1,1-trifluoro-3-chloropropane (e.g. using HF, optionally in the presence of a chromia-containing catalyst, preferably a zinc/chromia catalyst as described herein). Dehydrohalogenation of 1,1,1-trifluoro-3-chloropropane (e.g. using NaOH or KOH) produces 1243zf. Alternatively (not shown), 250fb may be dehydrochlorinated to 3,3,3-trichloropropene, followed by fluorination to 1243zf.

Thus, in a further aspect of the invention there is provided a process for preparing 1,1,1-trifluoro-2,3-dichloropropane (243db), which process comprises:

(a) telomerising ethylene and carbon tetrachloride (CCl₄) to produce 1,1,1,3-tetrachloropropane (250fb);

(b) converting 250fb to 3,3,3-trifluoropropene; and

(c) contacting 3,3,3-trifluoropropene with chlorine (Cl₂) in the presence of a catalyst to produce 1,1,1-trifluoro-2,3-dichloropropane (1243zf), wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal.

Step (a) of the above process typically comprises contacting ethylene with CCl₄ in the liquid and/or vapour phase in presence of a catalyst under conditions suitable to produce 1,1,1,3-tetrachloropropane.

Any suitable catalyst may be used in step (a), such as a catalyst which comprises iron, copper and/or peroxide.

Catalysts which comprise peroxide include benzoyl peroxide and di-t-butyl peroxide. Catalysts which comprise iron include iron powder and ferric/ferrous halides (e.g. chlorides). Catalysts which comprise copper include salts of copper such as copper halides (e.g. CuCl₂), copper sulphate and/or copper cyanide.

Typically, the catalysts which comprise copper and iron are used with a co-catalyst or ligand. Suitable co-catalysts include triethylorthoformate (HC(OEt)₃), nitrogen/phosphorus-containing ligands, and/or ammonium/phosphonium salts. Preferred nitrogen-containing ligands include amines (e.g. primary and secondary amines), nitriles and amides. Preferred phosphorus containing ligands include phosphates, phosphites (e.g. triethylphosphite) and phosphines. Preferred ammonium and phosphonium salts include ammonium and phosphonium halides (e.g. chlorides).

The catalyst for step (a) typically is used in an amount from about 0.01 to about 50 mol % (e.g. about 0.1 to about 10%), based on the molar sum of carbon tetrachloride and ethylene present. An excess of the carbon tetrachloride over ethylene generally is used. For example, the molar ratio of CCl₄:C₂H₄ typically is from about 1:1 to about 50:1, such as from about 1.1:1 to about 20:1, for example from about 1.2:1 to about 10:1 or about 1.5:1 to about 5:1.

The reaction temperature for step (a) typically is within the range of from 20 to 300° C., preferably from about 30 to about 250° C., such as from about 40 to about 200° C., e.g. from about 50 to about 150° C.

The reaction pressure for step (a) typically is within the range of from 0 to about 40 bara, preferably from about 1 to about 30 bara.

The reaction time for step (a) generally is from about 1 second to about 100 hours, preferably from about 10 seconds to about 50 hours, such as from about 1 minute to about 10 hours.

Step (a) can be carried out in any suitable apparatus, such as a static mixer, a tubular reactor, a stirred tank reactor or a stirred vapour-liquid disengagement vessel. Step (a) may be carried out batch-wise or continuously. Preferably, the 1,1,1,3-tetrachloropropane formed in step (a) is purified and/or isolated before it is fluorinated in step (b). This purification may conveniently be achieved, for example by distillation and/or extraction.

The conversion of 1,1,1,3-tetrachloropropane (250fb) to 3,3,3-trifluoropropene (1243zf) in step (b) above typically involves fluorination and dehydrohalogenation sub-steps.

For example, 250fb may be fluorinated to produce a compound of formula CF₃CH₂CH₂Cl (253fb), followed by dehydrohalogenation of the 253fb to produce 1243zf. This will be referred to hereinafter as route (b1).

Alternatively, 250fb may be dehydrochlorinated to produce 3,3,3-trichloropropene, followed by fluorination to produce 1243zf. This will be referred to hereinafter as route (b2).

Either or both routes (b1) and (b2) may be used to convert 1,1,1,3-tetrachloropropane to 3,3,3-trifluoropropene, depending on the choice of reagents and/or catalysts. The route taken and the number of steps involved may depend on factors such as the reaction conditions and the nature of catalyst employed (if any). Such factors are described in more detail below.

In route (b1), for example, 250fb may be fluorinated with HF in the presence of a catalyst to produce 253fb. Any suitable catalyst for HF fluorination may be used, such as compounds comprising aluminium (e.g. alumina-based catalysts) and/or chromium (e.g. chromia-based catalysts, especially zinc/chromia catalysts as described herein) and/or metal halides such as chlorides or fluorides (e.g. TiCl₄, SnCl₄ or SbF₅) and/or nitrogen-containing bases (e.g. amines and nitrogen-containing heterocycles such as pyridine).

253fb may then be dehydrohalogenated to 1243zf by any suitable method, for example by base-mediated (e.g. using a base comprising alkali or alkaline earth metal hydroxides or amides), thermal or metal catalysed (e.g. zinc/chromia-catalysed) dehydrohalogenation. The dehydrohalogenation may be conducted in the presence or absence of HF. Suitable reaction conditions for the dehydrohalogenation of the 253fb are described hereinafter in relation to the dehydrohalogenation step (iii) of a compound of formula CF₃CHFCH₂X (wherein X=Cl or F).

The fluorination and dehydrohalogenation reactions in step (b or route b1) using HF may be conducted simultaneously (i.e. in a one-pot process) or sequentially, optionally with separation/isolation of the 253fb prior to dehydrohalogenation. Preferably, route (b1) is carried out in one-pot using a zinc/chromia catalyst.

In route (b2), the dehydrochlorination and fluorination reactions may be carried out under substantially the same reaction conditions, i.e. in a one-pot process. Thus, 250fb may be contacted with HF in the presence of a catalyst to produce 1243zf, typically via 1,1,1,3-tetrafluoropropane. Suitable catalysts include compounds comprising aluminium (e.g. alumina or aluminium fluoride) and/or chromium (e.g. chromia-based catalysts, especially zinc/chromia catalysts as described herein), and/or metal halides such as chlorides or fluorides (e.g. TaF₅, TiCl₄, SnCl₄, SbCl₅ or SbF₅) and/or nitrogen-containing bases (e.g. amines and nitrogen containing heterocycles such as pyridine). Examples of catalysts compounds comprising aluminium include AlF₃, optionally mixed with one or more transition metal compounds.

Although HF is described as a suitable fluorination agent for step (b), any suitable fluorination agent may be used. For example, in an alternative embodiment, 1243zf may be produced in one pot by treating 250fb with NaF, KF, or amine:HF complexes such as Olah's reagent.

Typically, step (b) is carried out at a temperature of about 20 to about 500° C. For example, when using KF or Olah's reagent (pyrindinium poly(HF)), temperatures of about 50 to about 200° C. may be used. Alternatively, when using HF, higher temperatures may be employed, such as from about 100 to about 500° C. (e.g. about 120 to about 400° C. or about 150 to about 250° C.).

The temperature used may vary depending on the nature of the catalyst employed. For example, when a nitrogen-containing base is used, the preferred temperature may range from about 100 to about 250° C., whereas when a catalyst based on a compound of aluminium is employed, the preferred temperature may vary from about 200 to about 350° C. When a zinc/chromia catalyst is used for step (ii), the temperature typically ranges from about 150 to about 400° C., such as from about 150 to about 350° C., e.g. from about 150 to about 300° C. or from about 150 to about 250° C.

The reaction pressure for step (b) typically is within the range of from 0 to about 30 bara, preferably from about 1 to about 20 bara.

An excess of the fluorination agent is generally used in step (b), whether the 1243zf is produced via route (b1) or route (b2). For example, when using HF as the fluorination agent, a molar ratio of HF:organics of from about 1:1 to about 100:1, such as from about 3:1 to about 50:1, e.g. from about 6:1 to about 30:1 may be used.

The reaction time for step (b) generally is from about 1 second to about 100 hours, preferably from about 10 seconds to about 50 hours, such as from about 1 minute to about 10 hours. In a continuous process, typical contact times of the catalyst with the reagents is from about 1 to about 1000 seconds, such from about 1 to about 500 seconds or about 1 to about 300 seconds or about 1 to about 50, 100 or 200 seconds.

Step (b) can be carried out in any suitable apparatus, such as a static mixer, a tubular reactor, a stirred tank reactor or a stirred vapour-liquid disengagement vessel. Step (b) may be carried out batch-wise or continuously. Preferably, the 1243zf formed in step (b) is purified and/or isolated before it is chlorinated in step (c). This purification may conveniently be achieved, for example by distillation and/or extraction.

Step (b) is described in more detail towards the end of this specification in a further embodiment denoted the 1243zf preparation process.

The conditions for step (c) typically will be as defined above in the first embodiment of the invention.

In a preferred aspect of the invention, the 243db formed by the processes described herein is fluorinated to produce a compound of formula CF₃CHFCH₂X, wherein X is Cl or F. Thus, the invention provides a process for preparing a compound of formula CF₃CHFCH₂X, wherein X is Cl or F, the process comprising (i) contacting 3,3,3-trifluoropropene (1243zf) with chlorine (Cl₂) in the presence of a catalyst comprising activated carbon, alumina and/or an oxide of a transition metal to produce 1,1,1-trifluoro-2,3-dichloropropane (243db), and (ii) contacting the 243db with hydrogen fluoride (HF) in the presence of a fluorination catalyst to produce the compound of formula CF₃CHFCH₂X.

Any suitable fluorination catalyst may be used in step (ii), including but not limited to catalysts comprising activated carbon, alumina and/or an oxide of a transition metal (as described hereinbefore in relation to the chlorination step (i)) and supported (e.g. on carbon) or unsupported lewis acid metal halides, including TaX₅, SbX₅, SnX₄, TiX₄, FeCl₃, NbX₅, VX₅, AlX₃ (wherein X=F or Cl).

Catalysts comprising chromia are a preferred group of catalysts for use in step (ii). For example, chromia (Cr₂O₃) that has been modified by the addition of Zn, Mn, Zr, Ni, Al and/or Mg and/or a compound of one or more of these metals may be used. Suitable chromia-based catalysts include those described in EP-A-0502605, EP-A-0773061, EP-A-957074, WO 98/10862 and WO 2006/106353. A preferred chromia-based catalyst is a zinc/chromia catalyst.

By the term “zinc/chromia catalyst” we mean any catalyst comprising chromium or a compound of chromium and zinc or a compound of zinc. Such catalysts are known in the art, see for example EP-A-0502605, EP-A-0773061, EP-A-0957074 and WO 98/10862, which are incorporated by reference herein. However, the present inventors have surprisingly found that zinc/chromia catalysts may be used promote the dehydrohalogenation of 243db to produce 1233xf, and/or the fluorination of 1233xf to produce the compound of formula CF₃CFXCH₃, and/or the dehydrohalogenation of the compound of formula CF₃CFXCH₃ to produce 1234yf.

Typically, the chromium or compound of chromium present in the zinc/chromia catalysts of the invention is an oxide, oxyfluoride or fluoride of chromium such as chromium oxide.

The total amount of the zinc or a compound of zinc present in the zinc/chromia catalysts of the invention is typically from about 0.01% to about 25%, preferably 0.1% to about 25%, conveniently 0.01% to 6% zinc, and in some embodiments preferably 0.5% by weight to about 25% by weight of the catalyst, preferably from about 1 to 10% by weight of the catalyst, more preferably from about 2 to 8% by weight of the catalyst, for example about 4 to 6% by weight of the catalyst.

In other embodiments, the catalyst conveniently comprises 0.01% to 1%, more preferably 0.05% to 0.5% zinc.

The preferred amount depends upon a number of factors such as the nature of the chromium or a compound of chromium and/or zinc or a compound of zinc and/or the way in which the catalyst is made. These factors are described in more detail hereinafter.

It is to be understood that the amount of zinc or a compound of zinc quoted herein refers to the amount of elemental zinc, whether present as elemental zinc or as a compound of zinc.

The zinc/chromia catalysts used in the invention may include an additional metal or compound thereof. Typically, the additional metal is a divalent or trivalent metal, preferably selected from nickel, magnesium, aluminium and mixtures thereof. Typically, the additional metal is present in an amount of from 0.01% by weight to about 25% by weight of the catalyst, preferably from about 0.01 to 10% by weight of the catalyst. Other embodiments may comprise at least about 0.5% by weight or at least about 1% weight of additional metal.

The zinc/chromia catalysts used in the present invention may be amorphous. By this we mean that the catalyst does not demonstrate substantial crystalline characteristics when analysed by, for example, X-ray diffraction.

Alternatively, the catalysts may be partially crystalline. By this we mean that from 0.1 to 50% by weight of the catalyst is in the form of one or more crystalline compounds of chromium and/or one or more crystalline compounds of zinc. If a partially crystalline catalyst is used, it preferably contains from 0.2 to 25% by weight, more preferably from 0.3 to 10% by weight, still more preferably from 0.4 to 5% by weight of the catalyst in the form of one or more crystalline compounds of chromium and/or one or more crystalline compounds of zinc.

During use in a fluorination/dehydrohalogenation reaction the degree of crystallinity may change. Thus it is possible that a catalyst of the invention that has a degree of crystallinity as defined above before use in a fluorination/dehydrohalogenation reaction and will have a degree of crystallinity outside these ranges during or after use in a fluorination/dehydrohalogenation reaction.

The percentage of crystalline material in the catalysts of the invention can be determined by any suitable method known in the art. Suitable methods include X-ray diffraction (XRD) techniques. When X-ray diffraction is used the amount of crystalline material such as the amount of crystalline chromium oxide can be determined with reference to a known amount of graphite present in the catalyst (eg the graphite used in producing catalyst pellets) or more preferably by comparison of the intensity of the XRD patterns of the sample materials with reference materials prepared from suitable internationally recognised standards, for example NIST (National Institute of Standards and Technology) reference materials.

The zinc/chromia catalysts of the invention typically have a surface area of at least 50 m²/g and preferably from 70 to 250 m²/g and most preferably from 100 to 200 m²/g before it is subjected to pre-treatment with a fluoride containing species such as hydrogen fluoride or a fluorinated hydrocarbon. During this pre-treatment, which is described in more detail hereinafter, at least some of the oxygen atoms in the catalyst are replaced by fluorine atoms.

The zinc/chromia catalysts of the invention typically have an advantageous balance of levels of activity and selectivity. Preferably, they also have a degree of chemical robustness that means that they have a relatively long working lifetime. The catalysts of the invention preferably also have a mechanical strength that enables relatively easy handling, for example they may be charged to reactors or discharged from reactors using known techniques.

The zinc/chromia catalysts of the invention may be provided in any suitable form known in the art. For example, they may be provided in the form of pellets or granules of appropriate size for use in a fixed bed or a fluidised bed. The catalysts may be supported or unsupported. If the catalyst is supported, suitable supports include AlF₃, fluorinated alumina or activated carbon.

The zinc/chromia catalysts of the invention include promoted forms of such catalysts, including those containing enhanced Lewis and/or Brönsted acidity and/or basicity.

The amorphous catalysts which may be used in the present invention can be obtained by any method known in the art for producing amorphous chromia-based catalysts. Suitable methods include co-precipitation from solutions of zinc and chromium nitrates on the addition of ammonium hydroxide. Alternatively, surface impregnation of the zinc or a compound thereof onto an amorphous chromia catalyst can be used.

Further methods for preparing the amorphous zinc/chromia catalysts include, for example, reduction of a chromium (VI) compound, for example a chromate, dichromate, in particular ammonium dichromate, to chromium (III), by zinc metal, followed by co-precipitation and washing; or mixing as solids, a chromium (VI) compound and a compound of zinc, for example zinc acetate or zinc oxalate, and heating the mixture to high temperature in order to effect reduction of the chromium (VI) compound to chromium (III) oxide and oxidise the compound of zinc to zinc oxide.

The zinc may be introduced into and/or onto the amorphous chromia catalyst in the form of a compound, for example a halide, oxyhalide, oxide or hydroxide depending at least to some extent upon the catalyst preparation technique employed. In the case where amorphous catalyst preparation is by impregnation of a chromia, halogenated chromia or chromium oxyhalide, the compound is preferably a water-soluble salt, for example a halide, nitrate or carbonate, and is employed as an aqueous solution or slurry. Alternatively, the hydroxides of zinc and chromium may be co-precipitated (for example by the use of a base such as sodium hydroxide or ammonium hydroxide) and then converted to the oxides to prepare the amorphous catalyst. Mixing and milling of an insoluble zinc compound with the basic chromia catalyst provides a further method of preparing the amorphous catalyst precursor. A method for making amorphous catalyst based on chromium oxyhalide comprises adding a compound of zinc to hydrated chromium halide.

The amount of zinc or a compound of zinc introduced to the amorphous catalyst precursor depends upon the preparation method employed. It is believed that the working catalyst has a surface containing cations of zinc located in a chromium-containing lattice, for example chromium oxide, oxyhalide, or halide lattice. Thus the amount of zinc or a compound of zinc required is generally lower for catalysts made by impregnation than for catalysts made by other methods such as co-precipitation, which also contain the zinc or a compound of zinc in non-surface locations.

Any of the aforementioned methods, or other methods, may be employed for the preparation of the amorphous catalysts which may be used in the process of the present invention.

The zinc/chromia catalysts described herein are typically stabilised by heat treatment before use such that they are stable under the environmental conditions that they are exposed to in use. This stabilisation is often a two-stage process. In the first stage, the catalyst is stabilised by heat treatment in nitrogen or a nitrogen/air environment. In the art, this stage is often called “calcination”. Fluorination catalysts are then typically stabilised to hydrogen fluoride by heat treatment in hydrogen fluoride. This stage is often termed “pre-fluorination”.

By careful control of the conditions under which these two heat treatment stages are conducted, crystallinity can be induced into the catalyst to a controlled degree.

For example, an amorphous catalyst may be heat treated at a temperature of from about 300 to about 600° C., preferably from about 400 to 600° C., more preferably from 500 to 590° C., for example 520, 540, 560 or 580° C. for a period of from about 1 to about 12 hours, preferably for from about 2 to about 8 hours, for example about 4 hours in a suitable atmosphere. Suitable atmospheres under which this heat treatment can be conducted include an atmosphere of nitrogen or an atmosphere having an oxygen level of from about 0.1 to about 10% v/v in nitrogen. Other oxidizing environments could alternatively be used. For example, environments containing suitable oxidizing agents include, but are not limited to, those containing a source of nitrate, CrO₃ or O₂ (for example air). This heat treatment stage can be conducted in addition to or instead of the calcining stage that is typically used in the prior art to produce amorphous catalysts.

Conditions for the pre-fluorination stage can be selected so that they do not substantially introduce crystallinity into the catalyst. This may be achieved by heat treatment of the catalyst precursor at a temperature of from about 200 to about 500° C., preferably from about 250 to about 400° C. at atmospheric or super atmospheric pressure for a period of from about 1 to about 16 hours in the presence of hydrogen fluoride, optionally in the presence of another gas such as nitrogen.

Conditions for the pre-fluorination stage can be selected so that they induce a change in the crystallinity of the catalyst or so that they do not induce such a change. The present inventors have found that heat treatment of the catalyst precursor at a temperature of from about 250 to about 500° C., preferably from about 300 to about 400° C. at atmospheric or super atmospheric pressure for a period of from about 1 to about 16 hours in the presence of hydrogen fluoride, optionally in the presence of another gas such as air, can produce a catalyst in which the crystallinity is as defined above, for example from 0.1 to 8.0% by weight of the catalyst (typically from 0.1 to less than 8.0% by weight of the catalyst) is in the form of one or more crystalline compounds of chromium and/or one or more crystalline compounds of the at least one additional metal.

The skilled person will appreciate that by varying the conditions described above, such as by varying the temperature and/or time and/or atmosphere under which the heat treatment is conducted, the degree of crystallinity of the catalyst may be varied. Typically, for example, catalysts with higher degrees of crystallinity (e.g. from 8 to 50% by weight of the catalyst) may be prepared by increasing the temperature and/or increasing the calcination time and/or increasing the oxidising nature of the atmosphere under which the catalyst pre-treatment is conducted.

The variation of catalyst crystallinity as a function of calcination temperature, time and atmosphere is illustrated by the following table showing a series of experiments in which 8 g samples of a 6% zinc/chromia catalyst were subjected to calcination across a range of conditions and the level of crystallinity induced determined by X-Ray diffraction.

Calcination Calcination Atmosphere % Cryst Time Temperature nitrogen:air Cr₂O₃ (t, hrs) (T, ° C.) (D, v/v) Content 4 400.0 15 1 4 400.0 15 1 2 450.0 20 9 6 350.0 20 0 2 450.0 10 18 2 350.0 10 0 6 450.0 20 20 6 350.0 10 0 6 450.0 10 30 4 400.0 15 1 2 350.0 20 0

The pre-fluorination treatment typically has the effect of lowering the surface area of the catalyst. After the pre-fluorination treatment the catalysts of the invention typically have a surface area of 20 to 200 m²/g, such as 50 to 150 m²/g, for example less than about 100 m²/g.

In use, the zinc/chromia catalyst may be regenerated or reactivated periodically by heating in air at a temperature of from about 300° C. to about 500° C. Air may be used as a mixture with an inert gas such as nitrogen or with hydrogen fluoride, which emerges hot from the catalyst treatment process and may be used directly in fluorination processes employing the reactivated catalyst. Alternatively, the catalyst can be regenerated continuously whilst in use by introducing an oxidising gas into the reactor e.g. oxygen or chlorine.

Step (ii) can be carried out in any suitable apparatus, such as a static mixer, a tubular reactor, a stirred tank reactor or a stirred vapour-liquid disengagement vessel. Step (ii) may be carried out batch-wise or continuously and in the gas or liquid phase.

Step (ii) may be carried out simultaneously with step (i). In other words, the process may comprise contacting 3,3,3-trifluoropropene (1243zf) with chlorine (Cl₂) and HF in the presence of a catalyst comprising activated carbon, alumina and/or an oxide of a transition metal to produce a compound of formula CF₃CHFCH₂X, wherein X is Cl or F. Thus, in this process, the catalyst based on activated carbon, alumina and/or an oxide of a transition metal acts as both a chlorination and fluorination catalyst.

When steps (i) and (ii) are carried out simultaneously, the process conditions used (e.g. temperature, pressure and molar ratio of 1243:chlorine) typically are the same as set out above in relation to the first aspect of the invention for the chlorination of 1243zf to 243db (i.e. step (i)). The preferred temperature for this simultaneous process may be somewhat higher than for step (i) alone, such as from 0 to about 350° C., e.g. from about 50 to about 300° C.

Typically, when steps (i) and (ii) are carried out simultaneously, HF will be used in a molar excess compared to the amount of 1243zf and/or chlorine. For example, the molar ratio of HF:1243zf may be in the range of from about 1:1 to about 200:1, such as from about 2:1 to about 150:1, e.g. from about 5:1 to about 100:1.

In another aspect of the invention, the hydrofluorination step (ii) may be carried out subsequent to the chlorination step (i). The 243db formed in step (i) may be purified and/or isolated prior to fluorination in step (ii), e.g. by removal and/or recycling from the reaction vessel of some or all of the chlorine and/or 1243zf in step (i). For example, the 243db may be separated (e.g. by distillation, condensation and phase separation, and/or scrubbing with water or aqueous base) from the chlorine and 1243zf in step (i) and transferred to a different reaction vessel or zone for conducting the fluorination step (ii).

By conducting step (i) and (ii) consecutively and in separate reaction zones or vessels, the reagents, temperature, pressure and type of catalyst can be chosen to facilitate the chlorination and fluorination reactions, respectively, as explained below.

For example, a catalyst based on activated carbon may be preferred in step (i) and a chromia-based (e.g. zinc/chromia) catalyst may be preferred for step (ii). Alternatively/additionally, photochemical chlorination may be used in step (i), followed by zinc/chromia catalysed hydrofluorination in step (ii).

Step (i) can be conducted in the absence of HF, or with small amounts of HF (e.g. in order to prevent and/or retard excessive decomposition and/or coking of the catalyst), whereas a relatively high ratio of HF:243db can be used in step (ii). For example, a typical molar ratio of HF:1243zf in step (i) is from about 0.01:1 to about 10:1 (e.g. about 0.1 to about 5:1), whereas molar ratio of HF:243db in step (ii) is generally from about 1:1 to about 100:1 (e.g. about 3:1 to about 50:1).

Still further, higher temperature and/or pressure conditions may be used in the fluorination step (ii) compared to the chlorination step (i). Thus, step (i) may be conducted at a temperature of from about −100 to about 400° C. (e.g. from about −50 to about 250° C.), whereas step (ii) may be conducted at a temperature of from about 100 to about 380° C. (e.g. from about 200 to about 370° C.). Step (i) may be carried out at a pressure of from about 0.1 to about 20 bara (e.g. about 0.5 to about 10 bara), whereas step (ii) may be carried out at a pressure of from about 5 to about 28 bara (e.g. about 10 to about 25 bara).

Steps (i) and (ii) may both be carried out in the liquid phase or in the vapour phase. Alternatively, steps (i) and (ii) may be carried out in the liquid phase and vapour phase, respectively.

In another aspect of the invention, the compound of formula CF₃CHFCH₂X (wherein X is Cl or F) may be dehydrohalogenated to produce 2,3,3,3-tetrafluoropropene. 2,3,3,3-tetrafluoropropene is also known as HFO-1234yf or 1234yf. Unless otherwise stated, 2,3,3,3-tetrafluoropropene will be referred to hereinafter as 1234yf.

Thus the invention provides a process for preparing 1234yf, the process comprising (i) contacting 3,3,3-trifluoropropene (1243zf) with chlorine (Cl₂) in the presence of a catalyst based on activated carbon, alumina and/or an oxide of a transition metal to produce 1,1,1-trifluoro-2,3-dichloropropane (243db), (ii) contacting the 243db with hydrogen fluoride (HF) in the presence of a fluorination catalyst to produce a compound of formula CF₃CHFCH₂X, wherein X is Cl or F, and (iii) dehydrohalogenating the compound of formula CF₃CHFCH₂X to produce 1234yf.

Unless otherwise stated, as used herein, by the term “dehydrohalogenation” (or dehydrohalogenating), we refer to the removal of hydrogen chloride (HCl) or hydrogen fluoride (HF) from the compound of formula CF₃CHFCH₂X. Thus the term “dehydrohalogenation” includes “dehydrofluorination” and “dehydrochlorination” of the compound of formula CF₃CHFCH₂X.

Step (iii) of the process defined above may be carried out by any suitable reaction conditions effective to dehydrohalogenate (i.e. dehydrochlorinate or dehydrofluorinate) the compound of formula CF₃CHFCH₂X to produce 1234yf. Preferably, the dehydrohalogenation is carried out in the vapour and/or liquid phase and may be carried out at a temperature of from about −70 to about 1000° C. (e.g. about 0 to about 400° C.).

The process may be carried out at atmospheric sub- or super atmospheric pressure, preferably from about 0 to about 30 bara.

The dehydrohalogenation may be induced thermally, may be base-mediated and/or may be catalysed by any suitable catalyst. Suitable catalysts include metal and carbon based catalysts such as those comprising activated carbon, main group (e.g. alumina-based catalysts) and transition metals, such as chromia-based catalysts (e.g. zinc/chromia) or nickel-based catalysts (e.g. nickel mesh).

Step (iii) can be carried out in any suitable apparatus, such as a static mixer, a stirred tank reactor or a stirred vapour-liquid disengagement vessel. The process may be carried out batch-wise or continuously and in the liquid or gas phase.

One preferred method of effecting the dehydrohalogenation of the compound of formula CF₃CHFCH₂X to produce 1234yf is by contacting CF₃CHFCH₂X with a catalyst based on chromia such as those described in EP-A-0502605, EP-A-0773061, EP-A-957074, WO 98/10862 and WO 2006/106353 (e.g. a zinc/chromia catalyst). Thus, when both steps (ii) and (iii) are carried out in the presence of a catalyst based on chromia (e.g. a zinc/chromia catalyst), they may be carried out in a “one-pot” manner. Alternatively, when both steps (ii) and (iii) are carried out in the presence of a catalyst comprising chromia, the fluorination and dehydrohalogenation reactions may be carried out in two discrete steps, for example using two or more discrete reaction zones or vessels.

When both steps (ii) and (iii) are carried out in the presence of a catalyst based on chromia, the reaction conditions for each step (ii) and (iii) may be the same (e.g. in a one-pot process) or different. Preferably, the reaction conditions when both steps (ii) and (iii) are carried out in the presence of a catalyst based on chromia can be selected to be different (e.g. when using two or more discrete reaction zones or vessels) so as to optimise the fluorination and dehydrohalogenation reactions, respectively. This is explained in more detail below.

Fluorination step (ii) preferably is conducted at a temperature of from about 0 to about 390° C., such as from about 100 to about 380° C. or from about 200 to about 370° C. (e.g. from about 240 to about 260° C.). When conducted in the presence of a catalyst based on chromia (e.g. a zinc/chromia catalyst), step (b) preferably is conducted at a temperature of from about 200 to about 360° C., such as from about 240 to about 340° C.

It is currently considered to be advantageous to use a higher pressure in step (ii) (to promote fluorination) than in step (iii) (to promote dehydrohalogenation). Thus, step (ii) preferably is carried out from about 5 to about 28 bara, such as from about 10 to about 25 bara (e.g. 15 to 20 bara), whereas step (iii) preferably is carried out from about 0.01 to about 25 bara or about 0.1 to about 20 bara, such as from about 1 to about 10 bara (e.g. 1 to 5 bara).

Fluorination step (ii) is carried out by contacting 243db with HF. Step (iii) of the invention may be carried out in the presence of HF. For example residual HF from step (ii) may be present, and/or HF from a separate feed. Alternatively, step (iii) may be carried out in the absence of HF, for example following separation of the compound of formula CF₃CHFCH₂X from HF prior to step (iii), and with no additional co-feed of HF. In certain embodiments it may be desirable to use some HF in order to prevent and/or retard excessive decomposition of the organic feed and/or coking of the catalyst in step (iii).

When both steps (ii) and (iii) are carried out in the presence of a catalyst based on chromia (e.g. a zinc/chromia catalyst) and HF, the molar ratio of HF:organics can be selected to be different in each step so as to promote fluorination in step (ii) and dehydrohalogenation in step (iii). For example, the molar ratio of HF:organics (e.g. 243db) in step (ii) preferably is from about 1:1 to about 100:1, such as from about 2:1 to about 50:1, for example from about 5:1 to about 40:1 (e.g. from about 10:1 to about 30:1). For step (iii), the molar ratio of HF:organics (e.g. the compound of formula CF₃CHFCH₂X) preferably is from about 0.01:1 to about 50:1, such as from about 0.1:1 to about 40:1, for example from about 0.5:1 to about 30:1 or about 2:1 to about 15:1 (e.g. from about 5:1 to about 10:1).

Another way of decreasing the concentration of HF in step (iii) relative to step (ii) (thereby facilitating the fluorination/dehydrohalogenation reactions in these steps) is by adding a diluent gas (e.g. nitrogen) to step (iii).

Another preferred method of effecting the dehydrohalogenation of the compound of formula CF₃CHFCH₂X to produce 1234yf is by contacting CF₃CHFCH₂X with a base (base-mediated dehydrohalogenation).

This base-mediated dehydrohalogenation process of step (iii) comprises contacting the hydro(halo)fluoroalkane with base such as a metal hydroxide or amide (preferably a basic metal hydroxide or amide, e.g. an alkali or alkaline earth metal hydroxide or amide).

Unless otherwise stated, as used herein, by the term “alkali metal hydroxide”, we refer to a compound or mixture of compounds selected from lithium hydroxide, sodium hydroxide, potassium hydroxide, rubidium hydroxide and caesium hydroxide. Similarly, by the term “alkali metal amide”, we refer to a compound or mixture of compounds selected from lithium amide, sodium amide, potassium amide, rubidium amide and caesium amide.

Unless otherwise stated, as used herein, by the term “alkaline earth metal hydroxide”, we refer to a compound or mixture of compounds selected from beryllium hydroxide, magnesium hydroxide, calcium hydroxide, strontium hydroxide and barium hydroxide. Similarly, by the term “alkaline earth metal amide”, we refer to a compound or mixture of compounds selected from beryllium amide, magnesium amide, calcium amide, strontium amide and barium amide.

Typically, the base-mediated dehydrohalogenation process of step (iii) is conducted at a temperature of from −50 to 300° C. Preferably, the process is conducted at a temperature of from 20 to 250° C., for example from 50 to 200° C. The base-mediated dehydrohalogenation may be conducted at a pressure of from 0 to 30 bara.

The reaction time for the base-mediated dehydrohalogenation process of step (iii) may vary over a wide range. However, the reaction time will typically be in the region of from 0.01 to 100 hours, such as from 0.1 to 50 hours, e.g. from 1 to 20 hours.

Of course, the skilled person will appreciate that the preferred conditions (e.g. temperature, pressure and reaction time) for conducting the base-mediated dehydrohalogenation may vary depending on a number of factors such as the nature of the compound of formula CF₃CHFCH₂X, the base being employed, and/or the presence of a catalyst etc.

The base-mediated dehydrohalogenation process of step (iii) may be carried out in the presence or absence of a solvent. If no solvent is used, the compound of formula CF₃CHFCH₂X may be passed into or over molten base or hot base, for example in a tubular reactor. If a solvent is used, in some embodiments a preferred solvent is water, although many other solvents may be used. In some embodiments solvents such as alcohols (e.g. propan-1-ol), diols (e.g. ethylene glycol) and polyols such as polyethylene glycol (e.g. PEG200 or PEG300) may be preferred. These solvents can be used alone or in combination. In further embodiments, solvents from the class known as polar aprotic solvents may be preferred. Examples of such polar aprotic solvents include diglyme, sulfolane, dimethylformamide (DMF), dioxane, acetonitrile, hexamethylphosphoramide (HMPA), dimethyl sulphoxide (DMSO) and N-methyl pyrrolidone (NMP). The boiling point of the solvent is preferably such that it does not generate excessive pressure under reaction conditions.

A preferred base is an alkali metal hydroxide selected from the group consisting of lithium hydroxide, sodium hydroxide and potassium hydroxide, more preferably, sodium hydroxide and potassium hydroxide and most preferably potassium hydroxide.

Another preferred base is an alkaline earth metal hydroxide selected from the group consisting of magnesium hydroxide and calcium hydroxide, more preferably calcium hydroxide.

The base is typically present in an amount of from 1 to 50 weight % based on the total weight of the components which make up step (iii). Preferably, the base is present in an amount of from 5 to 30 weight %.

The molar ratio of base to compound of formula CF₃CHFCH₂X is typically from 1:20 to 50:1, preferably from 1:5 to 20:1, for example from 1:2 to 10:1.

As mentioned above, the base-mediated dehydrohalogenation may preferably employ water as the solvent. Thus, the dehydrohalogenation reaction may preferably use an aqueous solution of at least one base, such as an alkali (or alkaline earth) metal hydroxide, without the need for a co-solvent or diluent. However, a co-solvent or diluent can be used for example to modify the system viscosity, to act as a preferred phase for reaction by-products, or to increase thermal mass. Useful co-solvents or diluents include those that are not reactive with or negatively impact the equilibrium or kinetics of the process and include alcohols such as methanol and ethanol; diols such as ethylene glycol; ethers such as diethyl ether, dibutyl ether; esters such as methyl acetate, ethyl acetate and the like; linear, branched and cyclic alkanes such as cyclohexane, methylcyclohexane; fluorinated diluents such as hexafluoroisopropanol, perfluorotetrahydrofuran and perfluorodecalin.

The base-mediated dehydrohalogenation of step (iii) is preferably conducted in the presence of a catalyst. The catalyst is preferably a phase transfer catalyst which facilitates the transfer of ionic compounds into an organic phase from, for example, a water phase. If water is used as a solvent, an aqueous or inorganic phase is present as a consequence of the alkali metal hydroxide and an organic phase is present as a result of the fluorocarbon. The phase transfer catalyst facilitates the reaction of these dissimilar components. While various phase transfer catalysts may function in different ways, their mechanism of action is not determinative of their utility in the present invention provided that they facilitate the dehydrohalogenation reaction. The phase transfer catalyst can be ionic or neutral and is typically selected from the group consisting of crown ethers, onium salts, cryptands and polyalkylene glycols and derivatives thereof (e.g. fluorinated derivatives thereof).

An effective amount of the phase transfer catalyst should be used in order to effect the desired reaction, influence selectivity to the desired products or enhance the yield; such an amount can be determined by limited experimentation once the reactants, process conditions and phase transfer catalyst are selected. Typically, the amount of catalyst used relative to the amount of compound of formula CF₃CHFCH₂X present is from 0.001 to 20 mol %, such as from 0.01 to 10 mol %, e.g. from 0.05 to 5 mol %.

Crown ethers are cyclic molecules in which ether groups are connected by dimethylene linkages. Crown ethers form a molecular structure that is believed to be capable of receiving or holding the alkali metal ion of the hydroxide and to thereby facilitate the reaction. Particularly useful crown ethers include 18-crown-6 (especially in combination with potassium hydroxide), 15-crown-5 (especially in combination with sodium hydroxide) and 12-crown-4 (especially in combination with lithium hydroxide).

Derivatives of the above crown ethers are also useful, such as dibenzyl-18-crown-6, dicyclohexanyl-18-crown-6, dibenzyl-24-crown-8 and dibenzyl-12-crown-4. Other compounds analogous to the crown ethers and useful for the same purpose are compounds which differ by the replacement of one or more of the oxygen atoms by other kinds of donor atoms, particularly N or S. Fluorinated derivatives of all the above may also be used.

Cryptands are another class of compounds useful in the base-mediated dehydrohalogenation as phase transfer catalysts. These are three dimensional polymacrocyclic chelating agents that are formed by joining bridgehead structures with chains that contain properly spaced donor atoms. The donor atoms of the bridges may all be O, N, or S, or the compounds may be mixed donor macrocycles in which the bridge strands contain combinations of such donor atoms. Suitable cryptands include bicyclic molecules that result from joining nitrogen bridgeheads with chains of (—OCH₂CH₂—) groups, for example as in [2.2.2]cryptand (4,7,13,16,21,24-hexaoxa-1,10-diazabicyclo[8.8.8]hexacosane, available under the brand names Kryptand 222 and Kryptofix 222).

Onium salts that may be used as catalysts in the base-mediated process of the step (iii) include quaternary phosphonium salts and quaternary ammonium salts, which may be represented by the formulae R¹R²R³R⁴P⁺Z⁻ and R¹R²R³R⁴N⁺Z⁻, respectively. In these formulae, each of R¹, R², R³ and R⁴ typically represent, independently, a C₁₋₁₀ alkyl group, an aryl group (e.g. phenyl, naphthyl or pyridinyl) or an arylalkyl group (e.g. benzyl or C₁₋₁₀ alkyl-substituted phenyl), and Z⁻ is a halide or other suitable counterion (e.g. hydrogen sulphate).

Specific examples of such phosphonium salts and quaternary ammonium salts include tetramethylammonium chloride, tetramethylammonium bromide, benzyltriethylammonium chloride, methyltrioctylammonium chloride (available commercially under the brands Aliquat 336 and Adogen 464), tetra-n-butylammonium chloride, tetra-n-butylammonium bromide, tetra-n-butylammonium hydrogen sulphate, tetra-n-butylphosphonium chloride, tetraphenylphosphonium bromide, tetraphenylphosphonium chloride, triphenylmethylphosphonium bromide and triphenylmethylphosphonium chloride. Benzyltriethylammonium chloride is preferred for use under strongly basic conditions.

Other useful onium salts include those exhibiting high temperature stabilities (e.g. up to about 200° C.), for example 4-dialkylaminopyridinium salts, tetraphenylarsonium chloride, bis[tris(dimethylamino)phosphine]iminium chloride and tetrakis[tris(dimethylamino)phosphinimino]phosphonium chloride. The latter two compounds are also reported to be stable in the presence of hot, concentrated sodium hydroxide and, therefore, can be particularly useful.

Polyalkylene glycol compounds useful as phase transfer catalysts may be represented by the formula R⁶O(R⁵O)_(m)R⁷ wherein R⁵ is a C₁₋₁₀ alkylene group, each of R⁶ and R⁷ are, independently H, a C₁₋₁₀ alkyl group, an aryl group (e.g. phenyl, naphthyl or pyridinyl) or an arylalkyl group (e.g. benzyl or C₁₋₁₀ alkyl-substituted phenyl), and m is an integer of at least 2. Preferable both R⁶ and R⁷ are the same, for example they may both by H.

Such polyalkylene glycols include diethylene glycol, triethylene glycol, tetraethylene glycol, pentaethylene glycol, hexaethylene glycol, diisopropylene glycol, dipropylene glycol, tripropylene glycol, tetrapropylene glycol and tetramethylene glycol, monoalkyl glycol ethers such as monomethyl, monoethyl, monopropyl and monobutyl ethers of such glycols, dialkyl ethers such as tetraethylene glycol dimethyl ether and pentaethylene glycol dimethyl ether, phenyl ethers, benzyl ethers of such glycols, and polyalkylene glycols such as polyethylene glycol (average molecular weight about 300) and polyethylene glycol (average molecular weight about 400) and the dialkyl (e.g. dimethyl, dipropyl, dibutyl)ethers of such polyalkylene glycols.

Combinations of phase transfer catalysts from within one of the groups described above may also be useful as well as combinations or mixtures from more than one group. Crown ethers and quaternary ammonium salts are the currently preferred groups of catalysts, for example 18-crown-6 and its fluorinated derivatives and benzyltriethylammonium chloride.

In a further aspect of the invention, 1234yf may be prepared starting from the above-described chlorination of 1243zf to 243db, but then from a different route from 243db than defined above in steps (ii) and (iii). This alternative route involves the dehydrochlorination of 243db to produce 3,3,3-trifluoro-2-chloro-prop-1-ene (CF₃CCl═CH₂, 1233xf). 1233xf may then be fluorinated to produce a compound of formula CF₃CFXCH₃ (wherein X=Cl, or F), which may then be dehydrohalogenated to produce 1234yf.

Thus there is provided a process for preparing 1234yf comprising (w) contacting 1243zf with Cl₂ in the presence of a catalyst comprising activated carbon, alumina and/or an oxide of a transition metal to produce 243db, (x) converting 243db to 3,3,3-trifluoro-2-chloro-prop-1-ene (CF₃CCl═CH₂), (y) contacting CF₃CCl═CH₂ with a fluorinating agent to produce a compound of formula CF₃CFXCH₃, wherein X=Cl or F, and (z) dehydrohalogenating the compound of formula CF₃CFXCH₃ to produce 1234yf.

Step (w) corresponds to the process described hereinbefore for the chlorination of 1243zf to 243db, e.g. step (i).

The above process comprising steps (w), (x), (y) and (z) may be carried out batch-wise or continuously. Each step (w), (x), (y) and (z) may independently be carried out batch-wise or continuously.

3,3,3-trifluoro-2-chloro-prop-1-ene (CF₃CCl═CH₂) is also known as HFO-1233xf or 1233xf. Unless otherwise stated, this compound will be referred to as 1233xf. The compound of formula CF₃CFXCH₂ may be CF₃CFClCH₃, which is also known as HCFC-244cb or 244cb, or CF₃CF₂CH₃, which is also known as HFC-245cb or 245cb. Unless otherwise stated, these compounds will be referred to as 244cb and 245cb, respectively.

Step (x) of the invention comprises converting 243db to 1233xf. Thus, step (x) involves the dehydrochlorination of 243db to produce 1233xf. Step (x) preferably is carried out in a first reactor in the presence of a first catalyst. This reaction may be carried out in the liquid phase or the gas phase, preferably the gas phase.

The catalyst used in step (x) may be any suitable catalyst that is effective to dehydrochlorinate 243db. Preferred catalysts are those comprising activated carbon, alumina and/or an oxide of a transition metal. Such catalysts are described in more detail above in relation to the conversion of 1243zf to 243db. A further group of preferred catalysts for step (x) are supported (e.g. on carbon) or unsupported lewis acid metal halides, including TaX₅, SbX₅, SnX₄, TiX₄, FeCl₃, NbX₅, VX₅, AlX₃ (wherein X=F or Cl).

A preferred group of catalysts for step (x) are catalysts which comprise activated carbon, alumina and/or chromia. Catalysts based on chromia currently are particularly preferred. A preferred chromia-based catalyst is a zinc/chromia catalyst. Catalysts comprising activated carbon currently are also particularly preferred. The use of the same catalyst(s) for steps (w) and (x) allows these steps to be carried out simultaneously in “one-pot”.

The catalyst in step (x) may be used in an amount of from about 0.01 to about 50% by weight, such as from about 0.1 to about 30%, for example from about 0.5 to about 20%, based on the weight of 243db.

It is preferable for step (x) to be carried out in the presence of hydrogen fluoride (HF). For example, when alumina or an oxide of a transition metal is used as a catalyst in step (e.g. a chromia-based catalyst such as zinc/chromia), HF may be used to prevent and/or retard excessive decomposition of the catalyst. Step (x) may also be carried out in the presence of Cl₂, for example when steps (w) and (x) are carried out in simultaneously in a one-pot conversion of 1243zf to 1233xf.

Step (x) may be carried out at a temperature of from about −70 to about 450° C. and at atmospheric, sub- or super-atmospheric pressure, preferably from about 0 to about 30 bara.

Preferably, step (x) is conducted at a temperature of from about 0 to about 390° C., such as from about 100 to about 380° C. or from about 200 to about 370° C. (e.g. from about 240 to about 260° C.).

Step (x) preferably is carried out at a pressure of from about 0.01 to about 25 bara or about 0.1 to about 20 bara, such as from about 1 to about 10 bara (e.g. 1 to 5 bara).

Step (y) of the invention comprises contacting CF₃CCl═CH₂ with a fluorinating agent to produce a compound of formula CF₃CFXCH₃, wherein X=Cl or F. Thus, step (y) involves the fluorination of 1233xf to produce 244cb and/or 245cb. Step (y) preferably is carried out in a second reactor in the presence of a second catalyst. This reaction may be carried out in the liquid phase or the gas phase, preferably the liquid phase.

Any suitable fluorinating agent may be used in step (y), including any suitable source of nucleophilic fluoride, optionally in a polar aprotic or protic solvent. Examples of suitable fluorinating agents include HF, NaF, KF and amine:HF complexes such as Olah's reagent. HF is a preferred fluorinating agent, as is KF in a polar aprotic or protic solvent.

The catalyst used in step (y) may be any suitable catalyst that is effective to fluorinate 1233xf. Preferred catalysts are those comprising activated carbon, alumina and/or an oxide of a transition metal and/or supported or unsupported lewis acid metal halides as described above in relation to the chlorination of 1243zf to 243db and step (x).

Preferred catalysts for step (y) are those which comprise chromia (particularly for vapour phase reactions) and lewis acid metal halide catalysts (particularly for liquid phase reactions). A preferred chromia-based catalyst for use in step (y) is a zinc/chromia catalyst. The same catalyst may be used for step (x) and (y), e.g. a chromia-based catalyst.

Typically, step (y) is conducted at a temperature of from about −100 to about 400° C. and a pressure of 0 to about 50 bara.

If step (y) is carried out in the liquid phase, it preferably is conducted at a temperature of from about −50 to about 250° C., such as from about 0 to about 200° C. or from about 10 to about 150° C. (e.g. from about 50 to about 100° C.), and conducted at a pressure of from about 1 to about 50 bara or about 5 to about 40 bara, such as from about 10 to about 30 bara (e.g. 15 to 25 bara).

If step (y) is carried out in the gas phase, it preferably is conducted at a temperature of from about 0 to about 390° C., such as from about 100 to about 350° C. or from about 200 to about 300° C., and conducted at a pressure of from about 0.1 to about 30 bara or about 0.5 to about 25 bara, such as from about 1 to about 20 bara (e.g. 5 to 15 bara).

Steps (x) and (y) preferably are carried out in separate first and second reactors, respectively. Any suitable apparatus may be used as a reactor for steps (x) and (y), such as a static mixer, a stirred tank reactor or a stirred vapour-liquid disengagement vessel.

It is believed that there are advantages associated with the use of separate reactors for these two steps, including modifying the conditions in each reactor to facilitate the reactions in steps (x) and (y) respectively.

For example, step (x) can be carried out in the gas phase and step (y) in the liquid phase. A higher temperature can be used in step (x) compared to step (y). A higher pressure can be used in step (y) compared to step (x).

Step (x) can be carried out in the absence of HF whereas HF can be used as the fluorination agent in step (y). Alternatively, if HF is used in step (x), for example to stabilise the catalyst, it may be used in lower concentrations compared to step (y). For example, the molar ratio of HF:organics (e.g. 243db) in step (x) preferably is from about 0.01:1 to about 50:1, such as from about 0.1:1 to about 40:1, for example from about 0.5:1 to about 30:1 or about 2:1 to about 15:1 (e.g. from about 10:1 to about 20:1 or from about 5:1 to about 10:1). The molar ratio of HF:organics (e.g. 1233xf) in step (y) preferably is from about 1:1 to about 100:1, such as from about 2:1 to about 50:1, for example from about 5:1 to about 40:1 (e.g. from about 10:1 to about 30:1).

When separate reactors are used, 1233xf produced in step (x) may be transferred from the first reactor directly to the second reactor for fluorination in step (y). Preferably, however, 1233xf is subjected to a purification step before being passed to the second reactor. The purification may be achieved by separation of the 1233xf from any other products or reagents by one or more distillation, condensation or phase separation steps and/or by scrubbing with water or aqueous base.

In step (z), the compound of formula CF₃CFXCH₃ (wherein X=Cl or F) is converted to 1234yf by dehydrochlorination of 244cb (i.e. wherein X=Cl) and/or dehydrofluorination of 245cb (i.e. wherein X=F).

Step (z) of the process of the invention may be carried out in any suitable reactions conditions effective to dehydrohalogenate the compound of formula CF₃CFXCH₃ to produce 1234yf. The dehydrohalogenation may be carried out in the vapour and/or liquid phase and typically is carried out at a temperature of from about −70 to about 1000° C. (e.g. about 0 to about 400° C.). Step (c) may be carried out at atmospheric sub- or super atmospheric pressure, preferably from about 0 to about 30 bara.

The dehydrohalogenation may be induced thermally, may be base-mediated and/or may be catalysed by any suitable catalyst. Suitable catalysts include metal and carbon based catalysts such as those comprising activated carbon, main group (e.g. alumina-based catalysts) and transition metals, such as chromia-based catalysts (e.g. zinc/chromia) or nickel-based catalysts (e.g. nickel mesh).

One preferred method of effecting the dehydrohalogenation of the compound of formula CF₃CFXCH₃ to produce 1234yf is by contacting CF₃CFXCH₃ with a metal catalyst, such as a chromia-based (e.g. zinc/chromia) catalyst.

When the catalyst used in step (y) is the same as in step (z) (e.g. when using a chromia-based catalyst such as a zinc/chromia catalyst), steps (y) and (z) may be carried out in a “one-pot” manner, i.e. simultaneously. Alternatively, when both steps (y) and (z) are carried out in the presence of the same catalyst, the fluorination and dehydrohalogenation reactions may be carried out in two discrete steps, for example using two or more discrete reaction zones or reactors.

When both steps (y) and (z) are carried out in the presence of the same catalyst, the reaction conditions for each step (y) and (z) may be the same (e.g. in a one-pot process) or different. Preferably, the reaction conditions when steps (y) and (z) are carried out in the presence of the same catalyst can be selected to be different so as to optimise the fluorination and dehydrohalogenation reactions, respectively. This is explained in more detail below.

The preferred conditions for fluorination step (y) are set out above. Dehydrohalogenation step (z) may be carried out in the vapour or liquid phase, preferably the vapour phase. When conducted in the vapour phase, typically in the presence of a metal catalyst, such as a chromia-based (e.g. zinc/chromia) catalyst, step (z) preferably is conducted at a temperature of from about 200 to about 360° C., such as from about 240 to about 340° C.

It is currently considered to be advantageous to use a higher pressure in step (y) (to promote fluorination) than in step (z) (to promote dehydrohalogenation). Thus, step (z) preferably is carried out from about 0.01 to about 25 bara or about 0.1 to about 20 bara, such as from about 1 to about 10 bara (e.g. 1 to 5 bara).

Fluorination step (y) preferably is carried out by contacting 1233xf with HF. Step (z) of the invention may be carried out in the presence of HF. For example residual HF from step (y) may be present, and/or HF from a separate feed. Alternatively, step (z) may be carried out in the absence of HF, for example following separation of the compound of formula CF₃CFXCH₃ from HF prior to step (y), and with no additional co-feed of HF. In certain embodiments it may be desirable to use some HF in order to prevent and/or retard excessive decomposition of the organic feed and/or coking of the catalyst in step (z).

When both steps (y) and (z) are carried out in the presence of HF, the molar ratio of HF:organics can be selected to be different in each step so as to promote fluorination in step (y) and dehydrohalogenation in step (z). For example, the molar ratio of HF:organics (e.g. the compound of formula CF₃CFXCH₃) in step (z) preferably is from about 0.01:1 to about 50:1, such as from about 0.1:1 to about 40:1, for example from about 0.5:1 to about 30:1 or about 2:1 to about 15:1 (e.g. from about 10:1 to about 20:1 or from about 5:1 to about 10:1).

Another way of decreasing the concentration of HF in step (z) relative to step (y) (thereby facilitating the fluorination/dehydrohalogenation reactions in these steps) is by adding a diluent gas (e.g. nitrogen) to step (z).

Another preferred method of effecting the dehydrohalogenation of the compound of formula CF₃CFXCH₃ to produce 1234yf is by contacting CF₃CFXCH₃ with a base (base-mediated dehydrohalogenation). The conditions which may be used for base-mediated dehydrohalogenation step (z) broadly are the same as described above in relation to the dehydrohalogenation of the compound of formula CF₃CHFCH₂X in step (iii).

In a further embodiment, the subject invention provides a process for preparing 3,3,3-trifluoropropene (1243zf), the process comprising contacting a compound of formula CX₃CH₂CH₂X or CX₃CH═CH₂, with hydrogen fluoride (HF) in the presence of a zinc/chromia catalyst, wherein each X independently is F, Cl, Br or I, provided that in the compound of formula CX₃CH═CH₂, at least one X is not F. Unless otherwise stated, this will be referred to hereinafter as the 1243zf preparation process (of the invention).

In a preferred embodiment, this process relates to the reaction of a compound of formula CX₃CH₂CH₂X to produce 1243zf.

The compound of formula CX₃CH₂CH₂X represents any halopropane wherein X=F, Cl, Br or I. In a preferred aspect, X=F or Cl. Examples of compounds of formula CX₃CH₂CH₂X include 1,1,1,3-tetrachloropropane (CCl₃CH₂CH₂Cl, 250fb), 1,1,3-trichloro-1-fluoropropane (CCl₂FCH₂CH₂Cl), 1,3-dichloro-1,1-difluoropropane (CClF₂CH₂CH₂Cl), 3-chloro-1,1,1-trifluoropropane (CF₃CH₂CH₂Cl, 253fb) and 1,1,1,3-tetrafluoropropane (CF₃CH₂CH₂F, 254fb).

In one aspect, the compound of formula CX₃CH₂CH₂X is selected from 250fb, 253fb and 254fb. In a preferred embodiment, the compound of formula CX₃CH₂CH₂X is 253fb. In a further preferred embodiment, the compound of formula CX₃CH₂CH₂X is 254fb. In a particularly preferred embodiment, the compound of formula CX₃CH₂CH₂X is 250fb.

The compound of formula CX₃CH═CH₂ represents any halopropane wherein X=F, Cl, Br or I, provided that at least one X is not F. Preferably, X is F or Cl (provided that at least one X is not F). Examples of compounds of formula CX₃CH═CH₂ include 3,3,3-trichloropropene (CCl₃CH═CH₂), 3,3-dichloro-3-fluoropropene (CCl₂FCH═CH₂) and 3-chloro-3,3-difluoropropene (CClF₂CH═CH₂). In a preferred aspect, the compound of formula CX₃CH═CH₂ represents 3,3,3-trichloropropene.

The inventors have unexpectedly found that zinc/chromia catalysts are particularly effective for the fluorination and/or dehydrohalogenation reactions required by the 1243zf preparation process. In particular, the zinc/chromia catalysts are believed to be more active than other catalysts, such as chromia-based catalysts. This enables the 1243zf preparation process to be conducted using less forcing conditions (e.g. lower temperature and/or pressure) than would otherwise be necessary.

The zinc/chromia catalyst may be used in the 1243zf preparation process in an amount of from about 0.01 to about 50% by weight, such as from about 0.1 to about 30%, for example from about 0.5 to about 20%, based on the combined weight of organics (e.g. compound of formula CX₃CH₂CH₂X or CX₃CH═CH₂) and HF.

The 1243zf preparation process can be carried out in any suitable apparatus, such as a static mixer, a stirred tank reactor or a stirred vapour-liquid disengagement vessel. Preferably, the apparatus is made from one or more materials that are resistant to corrosion, e.g. Hastelloy® or Inconel®.

The 1243zf preparation process may be carried out batch-wise or (semi-) continuously. Preferably, the process of the invention is carried out continuously. Typically, the 1243zf preparation process is carried out in the vapour phase.

The process may be carried out at atmospheric, sub- or super atmospheric pressure, typically at from 0 to about 30 bara, preferably from about 1 to about 20 bara.

Typically, the 1243zf preparation process of the invention is carried out a temperature of from about 100° C. to about 500° C. (e.g. from about 150° C. to about 500° C. or about 100 to about 450° C.). Preferably, the process is conducted at a temperature of from about 150° C. to about 450° C., such as from about 150° C. to about 400° C., e.g. from about 200° C. to about 350° C. Lower temperatures may also be used in the process of the invention, for example in the conversion of 250fb to 1243zf, such as from about 150° C. to about 350° C., e.g. from about 150° C. to about 300° C. or from about 150° C. to about 250° C.

The 1243zf preparation process typically employs a molar ratio of HF:organics of from about 1:1 to about 100:1, such as from about 3:1 to about 50:1, e.g. from about 4:1 to about 30:1 or about 5:1 or 6:1 to about 20:1 or 30:1.

The reaction time for the 1243zf preparation process generally is from about 1 second to about 100 hours, preferably from about 10 seconds to about 50 hours, such as from about 1 minute to about 10 or 20 hours. In a continuous process, typical contact times of the catalyst with the reagents is from about 1 to about 1000 seconds, such from about 1 to about 500 seconds or about 1 to about 300 seconds or about 1 to about 50, 100 or 200 seconds.

The 1243zf preparation process is particularly effective for preparing 3,3,3-trifluoropropene (1243zf) by contacting 1,1,1,3-tetrachloropropane (250fb) with hydrogen fluoride (HF) in the presence of a zinc/chromia catalyst.

250fb may be purchased from common suppliers of halogenated hydrocarbons, such as Apollo Scientific, Stockport, UK. Alternatively, 250fb may be prepared by the telomerisation of carbon tetrachloride (CCl₄) and ethylene (see, for example, J. Am. Chem. Soc. Vol. 70, p 2529, 1948, which is incorporated herein by reference).

The conversion of 250fb to 1243zf typically involves fluorination and dehydrohalogenation sub-steps.

For example, 250fb may be fluorinated to produce a compound of formula CX₃CH₂CH₂Cl (wherein X=Cl or F), as illustrated in the scheme below. 1243zf may be produced by a final dehydrochlorination step of the compound of formula CX₃CH₂CH₂Cl wherein X=F. This is illustrated below as route (a).

Alternatively, 250fb may be dehydrochlorinated to produce 3,3,3-trichloropropene, followed by step-wise fluorination to produce 1243zf. This is illustrated above as route (b). Routes (a) and (b) correspond to routes (b1) and (b2), respectively, as described herein in relation to step (b) of the process of the invention.

Either or both routes (a) and (b) may be operable to convert 250fb to 1243zf. For example, CCl₂FCH₂CHCl in route (a) may be dehydrochlorinated to produce CCl₂FCH═CH₂ in route (b). It is anticipated that some of these reactions may occur spontaneously if HF and 250fb are mixed at elevated temperatures, but the reaction will not go to completion in the absence of a zinc/chromia catalyst in any reasonable timescale.

Surprisingly, the inventors have found that zinc/chromia catalysts are effective at facilitating the one-pot conversion of 250fb and HF to 1243zf. In particular, the activity of the catalyst is believed to allow less forcing conditions (e.g. lower temperatures) compared to known (vapour phase) processes for producing 1243zf, whilst maintaining excellent conversion of 250fb and selectivity to 1243zf.

The invention will now be illustrated by the following non-limiting Examples.

EXAMPLE 1 Chlorination of 3,3,3-trifluoropropene (1243zf) at Atmospheric Pressure

1.1 g of activated carbon catalyst was loaded into a 1.25 cm (0.5″)×30 cm Inconel reactor tube. The catalyst was dried under flowing nitrogen (c.a. 10 ml/min) at 250° C. for 2 hours. The tubes were then cooled to the reaction temperatures shown in Tables 1a and 1b below prior to starting the feed flows, chlorine (c.a. 2 ml/min) and 1243zf (c.a. 6 ml/min). Samples of the reaction gases exiting the reactor zone were taken and analysed by GC and GC-MS (see Table 1b). An additional series of experiments were conducted using an empty tube containing no catalyst (see Table 1a).

TABLE 1A (no catalyst): N₂ = 9 ml/min; Cl₂ = 2 ml/min, 1243zf = 6 ml/min Tem- 1243zf per- Con- 1233 ature version 1243zf total* 1223xd 243db 1213xa Minors ° C. (%) (mol %) (mol %) (mol %) (mol %) (mol %) (mol %) 50 2.4 97.6 1.4 0.3 0.2 0.0 0.6 100 0.7 99.3 0.3 0.1 0.1 0.0 0.2 150 0.7 99.3 0.3 0.0 0.2 0.0 0.1 200 0.7 99.3 0.1 0.0 0.4 0.0 0.1 250 2.1 97.9 1.2 0.1 0.7 0.0 0.2

TABLE 1b (1.1 g activated carbon): N₂ = 10 ml/min; Cl₂ = 2 ml/min; 1243zf = 6 ml/min 1233 Temperature 1243zf 1243zf total* 1223xd 243db 1213xa Minors ° C. Conversion (%) (mol %) (mol %) (mol %) (mol %) (mol %) (mol %) 100 16.5 83.5 9.8 0.2 5.2 0.0 1.3 125 40.7 59.3 1.8 0.6 37.9 0.0 0.4 150 64.8 35.2 10.8 0.2 52.2 0.0 1.5 175 74.1 25.9 18.8 0.8 47.0 0.6 6.9 200 65.0 35.0 29.6 2.6 20.2 1.8 10.9 250 74.7 25.3 66.4 1.7 3.0 0.1 3.6 *Includes both 1233 isomers CF₃CCl = CH₂ (1233xf) and CF₃CH = CClH (1233zd) 1223xd = CF₃CCl = CHCl 1213xa = CF₃CCl = CCl₂

EXAMPLE 2 Chlorination of 3,3,3-trifluoropropene (1243zf) at Atmospheric Pressure

4.0 g of activated carbon catalyst was loaded into a 1.25 cm (0.5″)×30 cm Inconel reactor tube. The catalyst was dried under flowing nitrogen (c.a. 30 ml/min) at 250° C. for 1.5 hours. The tube was then cooled to the reaction temperatures shown in the Table below prior to starting the feed flows nitrogen (0 or 8 ml/min), chlorine (8 ml/min) and 1243zf (8 ml/min). Samples of the reaction gases exiting the reactor zone were taken and analysed by GC and GC-MS.

TABLE 2 Feed flows and conditions 1243zf 8 8 8 8 8 (mls/min) Cl₂ 8 8 8 8 8 (mls/min) N₂ 8 0 0 0 0 (mls/min) Reactor 150 150 175 185 200 Temperature (° C.) Reactor off-gas analysis (mol %) 1243zf 14.43 5.48 5.04 17.60 22.70 1233xf 28.11 33.49 48.29 61.89 50.94 1233zd 0.43 0.21 0.19 2.09 2.20 1223xd 1.29 0.80 0.87 5.00 7.52 1213xa 0.02 0.02 0.03 0.36 0.75  243db 50.61 55.24 37.66 9.59 9.81 Unknown 5.11 4.76 7.92 3.49 6.08 Total

Comparison of the results in Tables 1b and 2 with the results in Table 1a shows that activated carbon is a surprisingly effective catalyst for the conversion of 1243zf to 243db (and the onward conversion of 243db to 1233xf).

EXAMPLE 3 Single Stage Chlorofluorination of 3,3,3-trifluoropropene (1243zf)

A 1.25 cm (0.5″)×30 cm Inconel reactor tube loaded with 4 g 5.2% zinc/chromia catalyst. The catalyst was dried under flowing nitrogen (50 ml/min) for 2 hours at 250° C. After the drying time, HF (5-8 ml/min) was introduced into the nitrogen stream to begin fluorination of the catalyst. The temperature was ramped to 380° C. at 40° C./min and held there for 16 hours. After 2-3 hours HF breakthrough was detected in the reactor off-gas and the nitrogen flow was switched off. After this treatment the reactor temperature was reduced to the temperatures indicated in Table 3 and a mixture comprising HF (12 ml/min), 1243zf (3.2 ml/min) and chlorine (3 ml/min) passed through it. Samples of the reactor off-gas were taken and analysed by GC and GC-MS. The GC was calibrated using known standards to determine response factors and an average response factor was used to quantify unknowns.

TABLE 3 (4 g Zn/Cr catalyst): HF = 12 ml/min; 1243zf = 3.2 ml/min; Cl₂ = 3 ml/min Temperature ° C. Product (mol %) 200 220 240 280 300 320 350 1243zf 49.0 54.9 61.8 65.2 65.9 55.8 30.9 1233xf 5.7 12.5 21.1 29.1 30.5 37.7 45.2 1223xd 12.8 9.8 4.5 1.0 0.5 0.4 0.0  243db 32.6 22.6 12.2 2.7 1.4 1.6 4.7 Others including 0.0 0.2 0.3 1.9 1.6 4.6 19.2 1234yf

Comparison of the results in Tables 1a and 2 shows that zinc/chromia is a surprisingly effective catalyst for the conversion of 1243zf to 243db (and the onward conversion of 243db to 1233xf).

EXAMPLE 4 Single Stage Dehydrohalogenation of CF₃CFHCH₂F (245eb) to 1234yf

A 1.25 cm (0.5″)×30 cm Inconel reactor tube loaded with 4 g 5.2% zinc/chromia catalyst. The catalyst was dried under flowing nitrogen (50 ml/min) for 2 hours at 250° C. After the drying time, HF (5-8 ml/min) was introduced into the nitrogen stream to begin fluorination of the catalyst. The temperature was ramped to 380° C. at 40° C./min and held there for 16 hours. After 2-3 hours HF breakthrough was detected in the reactor off-gas and the nitrogen flow was switched off. After this treatment the reactor temperature was reduced to the temperatures shown in Table 4 and a mixture comprising nitrogen and 245eb passed over it. Samples of the reactor off-gas were taken and analysed by GC and GC-MS. The GC was calibrated using known standards to determine response factors and an average response factor was used to quantify unknowns.

TABLE 4 Nitrogen flow 8 ml/min, 245eb flow 2 ml/min Tem- perature ° C. Product 200 225 250 275 300 325 350 375 400 1234yf 0.4 0.9 2.4 17.7 40.7 51.8 88.8 96.4 100.0 1243zf 0.1 0.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0  245eb 99.2 97.2 93.2 71.2 59.2 48.2 2.9 0.0 0.0  245cb 0.2 1.7 4.3 11.1 0.0 0.0 8.2 3.6 0.0

The results in Table 3 show that zinc/chromia is a surprisingly effective catalyst for the dehydrofluorination of 245eb to 1234yf.

EXAMPLE 5 Hydrofluorination of 250fb (CCl₃CH₂CH₂Cl) at Elevated Pressure

The reactor, made from an Inconel tube 30 cm×0.5 inches, was charged with 6 g of a 5.2% Zn/Chromia catalyst which was essentially amorphous in character, which was treated as follows:

The catalyst was first dried by heating under nitrogen (80 ml/min) at 250° C. and 3 barg for 48 hours. Next, pre-fluorination of the catalyst was begun by introducing HF (4 ml/min) into the nitrogen stream and increasing the temperature to 300° C. for 16 hours. During the last 5 hours the nitrogen flow was reduced steadily to zero. The temperature was then ramped to 380° C. at 25° C./hr and held at 380° C. for 7 hours and then cooled to 250° C. at 25° C./hr.

A feed mixture comprising 250fb (3 ml/min) and HF (45 ml/min) was then passed over the catalyst at 15 barg and 200° C. The gases exiting the reactor were periodically sampled and analysed by GC after passing through an alkaline scrubber to remove acid gases. The only products detected in the reactor off-gases following removal of the acid gases were the desired product 1243zf (91 mol %, CF₃CH═CH₂) and 1,1-difluoro-1,3-dichloropropane (9 mol %, CF₂ClCH₂CH₂Cl).

It is believed that the 1,1-difluoro-1,3-dichloropropane could be converted to 1243zf by altering the reaction conditions (e.g. by increasing the temperature and/or contact time). In this way, 250fb could be fully converted in 100% selectivity to 1243zf in a single pass.

EXAMPLE 6 Hydrofluorination of 250fb (CCl₃CH₂CH₂Cl) at Atmospheric Pressure

The reactor, made from an Inconel tube 30 cm×0.5 inches, was loaded with 2.0 g of a 5.2% wt Zn on chromia catalyst which was essentially amorphous in character. The catalyst was then dried under nitrogen (80 ml/min) at 250° C. for 3 hours. HF (20 ml/min) was then introduced into the nitrogen flow and pre-fluorination of the catalyst commenced. When HF was detected in the reactor off-gases the reactor temperature was ramped from 250° C. to 370° C. at 25° C./hr and maintained there for 7 hours before being cooled back to 200° C. at 25° C./hr.

A feed mixture comprising 250fb (1 ml/min), HF (25 ml/min) and nitrogen (30 ml/min) was fed to the reactor at 200° C. for a total of 15 hours. The gases exiting the reactor were scrubbed with a an alkaline solution to remove acid gases and analysed by GC-MS and GC. The only species identified in the scrubbed reactor off-gases throughout the whole experiment was 1243zf.

Examples 5 and 6 demonstrate that the reaction of 250fb with HF using a zinc/chromia catalyst selectively produces 1243zf under very mild conditions.

EXAMPLE 7 Vapour Phase Conversion of 254fb (CF₃CH₂CH₂F) to 1243zf (CF₃CH═CH₂)

The reactor, made from an Inconel tube 30 cm×0.5 inches was loaded with 2.0 g of a 5.2% wt Zn on chromia catalyst which was essentially amorphous in character. The catalyst was then dried under nitrogen (80 ml/min) at 250° C. for 3 hours. HF (20 ml/min) was then introduced into the nitrogen flow and pre-fluorination of the catalyst commenced. When HF was detected in the reactor off-gases the reactor temperature was ramped from 250° C. to 370° C. at 25° C./hr and maintained there for 7 hours before being cooled back to 200° C. at 25° C./hr.

Mixtures of HF and 254fb were then fed across the catalyst at various temperatures and ratio's to demonstrate the conversion of 254fb to 1243zf. Nitrogen carrier gas flows were used to aid delivery of the feeds to the reactor. The gases exiting the reactor were analysed by GC-MS and GC. The results are summarised in the Table below:

Temperature (° C.) 200 225 250 200 225 250 275 300 300 225 250 254fb feed 13.5 12.1 16.7 20.4 22.9 10.6 12.8 10.0 1.0 4.9 4.9 (ml/min) HF feed 27.9 27.9 27.6 34.3 35.3 35.4 35.2 35.6 35.3 0 0 (ml/min) Ratio 2.1 2.3 1.7 1.7 1.5 3.3 2.8 3.6 35.4 N/A N/A HF:254fb Total N₂ flow 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 5 5 (ml/min) ROG* 254tb 93.3 50.1 14.8 93.3 71.9 17.4 1.5 0.1 0.7 1.3 0.1 (mol %) ROG* 6.7 49.9 85.2 6.7 28.1 82.6 98.5 99.9 99.3 98.7 99.9 1243zf (mol %) *ROG = Reactor Off-gas composition

As can be seen the conversion of 254fb to 1243xf is clean and facile over a zinc/chromia catalyst at moderate conditions. 

The invention claimed is:
 1. A process for preparing 1,1,1-trifluoro-2,3-dichloropropane (243 db), which process comprises (i) contacting 3,3,3-trifluoropropene (1243zf) with chlorine in the presence of a catalyst, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal.
 2. A process according to claim 1 wherein the process is conducted at a temperature of from about −100 to about 400° C. and a pressure of from 0 to about 30 bara.
 3. A process according to claim 1 the molar ratio of 1243zf:chlorine is from about 10:1 to about 1:5.
 4. A process for preparing 1,1,1-trifluoro-2,3-dichloropropane (243 db) comprising the step of converting 1,1,1,3-tetrachloropropane (250fb) to produce 3,3,3-trifluoropropene (1243zf), and contacting the 1243zf with chlorine in the presence of a catalyst, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal.
 5. A process for preparing 1,1,1-trifluoro-2,3-dichloropropane (243 db)—comprising the steps (a) of telomerising ethylene and carbon tetrachloride (CCl₄) to produce 1,1,1,3-tetrachloropropane (250fb), (b) converting the 250fb to produce 3,3,3-trifluoropropene (1243zf), and contacting the (1243zf) with chlorine in the presence of a catalyst, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal.
 6. A process according to claim 5 wherein step (a) comprises contacting ethylene with CCl₄ in the liquid and/or vapour phase in the presence of a catalyst in an amount of from about 0.01 to about 50 mol %.
 7. A process according to claim 6 wherein step (a) the catalyst comprises iron, copper and/or peroxide.
 8. A process according to claim 5 wherein step (a) the molar ratio of CCl₄:ethylene is from about 1:1 to about 50:1.
 9. A process according to claim 5 wherein step (a) is conducted at a temperature of from about 20 to about 300° C. and a pressure of from 0 to about 40 bara.
 10. A process according to claim 5 wherein the 1,1,1,3-tetrachloropropane is purified before conversion to 3,3,3-trifluoropropene (1243zf).
 11. A process according to claim 4 wherein the step of converting 250fb to 1234zf further comprises fluorination of 1,1,1,3-tetrachloropropene to produce a compound of formula CF₃CH₂CH₂Cl (253fb), followed by dehydrohalogenation of the 253fb to produce 1243zf.
 12. A process according to claim 11 further comprising contacting 250fb with HF in the presence of a catalyst (e.g. a zinc/chromia catalyst) to produce 1243zf.
 13. A process according to claim 4 wherein the step of converting 250fb to 1234zf is carried out at a temperature of from about 20 to about 500° C. and a pressure of from 0 to about 30 bara.
 14. A process according to claim 12 wherein the molar ratio of HF:organics is from about 1:1 to about 100:1 in the step of converting 250fb to 1234zf further.
 15. A process comprising the steps of (i) contacting 3,3,3-trifluoropropene (1243zf) with chlorine in the presence of a catalyst, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal to produce 1,1,1-trifluoro-2,3-dichloropropane (243 db); and (ii) contacting the 243 db with hydrogen fluoride (HF) in the presence of a fluorination catalyst to produce the compound of formula CF₃CHFCH₂X, wherein X is Cl or F.
 16. A process according to claim 15, wherein steps (i) and (ii) are conducted simultaneously.
 17. A process according to claim 16 wherein the molar ratio of HF:1243zf is from about 1:1 to about 200:1.
 18. A process according to claim 15 wherein step (ii) is carried out subsequent to step (i).
 19. A process according to claim 18 wherein the 243 db formed in step (i) is separated and/or purified prior to fluorination in step (ii).
 20. A process according to claim 18 wherein the fluorination catalyst in step (ii) is a chromia catalyst, preferably a zinc/chromia catalyst.
 21. A process according to claim 18 wherein step (i) is conducted in the absence of HF.
 22. A process according to claim 18 wherein step (i) is conducted in the presence of HF, wherein the molar ratio of HF:1243zf is from about 0.01:1 to about 10:1.
 23. A process according to claim 15 wherein the molar ratio of HF:243 db is from about 1:1 to about 100:1.
 24. A process according to claim 18 wherein step (i) is conducted at a temperature of from about −100 to about 400° C. and a pressure of from about 0.1 to about 20 bara, and step (ii) is conducted at a temperature of from about 100 to about 380° C. and a pressure of from about 5 to about 28 bara.
 25. A process according to claim 15 wherein steps (i) and (ii) are both carried out in the vapour phase.
 26. A process according to claim 15 wherein step (i) is carried out in the liquid phase and step (ii) is carried out in the vapour phase.
 27. A process according to claim 15 further comprising the step (iii) of dehydrohalogenating the compound of formula CF₃CHFCH₂X to produce a 2,3,3,3-tetrafluoropropene (1234y f).
 28. A process comprising the steps of: (w) contacting 3,3,3-trifluoropropene (1243zf) with chlorine in the presence of a catalyst comprising activated carbon, alumina and/or an oxide of a transition metal to produce 1,1,1-trifluoro-2,3-dichloropropane (243 db); and (x) converting the 243 db to 3,3,3-trifluoro-2-chloroprop-1-ene (CF₃CCl═CH₂, 1233xf).
 29. A process according to claim 28 wherein step (x) is carried out in the presence of a catalyst selected from catalysts comprising activated carbon, catalysts comprising alumina, catalysts comprising an oxide of a transition metal, lewis acid metal halide catalysts and mixtures thereof.
 30. A process according to claim 28 wherein step (x) is carried out at a temperature of from about −70 to about 450° C. and a pressure of from 0 to about 30 bara.
 31. A process comprising the steps of (w) contacting 3,3,3-trifluoropropene (1243zf) with chlorine in the presence of a catalyst, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal to produce 1,1,1-trifluoro-2,3-dichloropropane (243 db); (x) converting 243 db to 3,3,3-trifluoro-2-chloroprop-1-ene (CF₃CCl═CH₂, (1233xf); and (y) contacting the 1233xf with a fluorinating agent to produce a compound of formula CF₃CFXCH₃, wherein X=Cl or F.
 32. A process according to claim 31 wherein step (y) is carried is carried out at a temperature of from about −100 to about 400° C. and a pressure of from 0 to about 50 bara.
 33. A process according to claim 31 wherein the fluorinating agent is hydrogen fluoride (HF).
 34. A process according to claim 31 wherein step (y) is carried out in the presence of a catalyst selected from catalysts comprising activated carbon, catalysts comprising alumina, catalysts comprising an oxide of a transition metal, lewis acid metal halide catalysts and mixtures thereof.
 35. A process according to claim 31 wherein steps (x) and (y) are conducted in separate reactors.
 36. A process according to claim 31 wherein step (x) is carried out in the vapour phase.
 37. A process according to claim 36 wherein step (y) is carried out in the presence of a catalyst selected from catalysts comprising activated carbon, alumina and/or an oxide of a transition metal.
 38. A process according to claim 36 wherein step (y) is carried out at a temperature of from about 0 to about 390° C. and a pressure of from 0.1 to about 30 bara, preferably at a temperature of from about 200 to about 370° C. and a pressure of from about 1 to about 10 bara.
 39. A process according to claim 31 wherein step (x) is carried out in the liquid phase.
 40. A process according to claim 39 wherein step (y) is carried out in the presence of a lewis acid metal halide catalyst.
 41. A process according to claim 39 wherein step (y) is carried out at a temperature of from about −50 to about 250° C. and a pressure of from about 1 to about 50 bara, preferably at a temperature of from about 10 to about 150° C. and a pressure of from about 10 to about 30 bara.
 42. A process according to claim 28 wherein step (x) is conducted in the presence of HF.
 43. A process according to claim 42 wherein the molar ratio of HF:organics in step (x) is from about 0.01:1 to about 50:1, preferably from about 2:1 to about 15:1.
 44. A process according to claim 33 wherein the molar ratio of HF:organics in step (y) is from about 1:1 to about 100:1, preferably from about 5:1 to about 40:1.
 45. A process comprising the steps of (w) contacting 3,3,3-trifluoropropene (1243zf) with chlorine in the presence of a catalyst, wherein the catalyst comprises activated carbon, alumina and/or an oxide of a transition metal to produce 1,1,1-trifluoro-2,3-dichloropropane (243 db); (x) converting 243 db to 3,3,3-trifluoro-2-chloroprop-1-ene (CF₃CCl═CH₂, (1233xf); (y) contacting the 1233xf with a fluorinating agent to produce a compound of formula CF₃CFXCH₃, wherein X=Cl or Fl; and (z) dehydrohalogenating the compound of formula CF₃CFXCH₃ to produce 1234yf.
 46. A process according to claim 45 wherein the dehydrohalogenation step (z) is carried out at a temperature of from −70 to 1000° C. and a pressure of from 0 to about 30 bara.
 47. A process according to claim 45 wherein step (z) is carried out by metal catalysed dehydrohalogenation.
 48. A process according to claim 47 wherein step (z) is carried out at a temperature of from about 0 to about 400° C. and a pressure of from 0.01 to about 25 bara, preferably from about 200 to about 360° C. and from about 1 to about 10 bara.
 49. A process according to claim 47 wherein step (z) is conducted in the presence of HF.
 50. A process according to claim 49 wherein the wherein the molar ratio of HF:organics in step (z) is from about 0.01:1 to about 50:1, preferably from about 2:1 to about 15:1.
 51. A process according to any of claims 47 wherein step (z) is carried out simultaneously with step (y).
 52. A process according to claim 45 wherein step (z) is carried out by contacting the compound of formula CF₃CFXCH₃ with a base.
 53. A process according to claim 52 wherein step (z) is carried out at a temperature of from about −50 to about 300° C., preferably from about 20 to about 250° C.
 54. A process according to claim 52 wherein the base is selected from the group consisting of: a metal hydroxide, including alkali metal hydroxides, sodium hydroxide and potassium hydroxide; alkaline earth metal hydroxide, including calcium hydroxide a metal amide and mixtures thereof.
 55. A process according to claim 52 wherein step (z) is carried out in a solvent, preferably wherein the solvent is selected from water, alcohols, diols, polyols, polar aprotic solvents and mixtures thereof, and wherein the process optionally is carried out in the presence of a co-solvent or diluent.
 56. A process according to claim 52 wherein step (z) is carried out in the presence of a catalyst, preferably wherein the catalyst is a crown ether or a quaternary ammonium salt. 